NOTICE Whenever you see the symbols shown below, heed their instructions! NOTICE is used to address prac- Always follow safe operating and main- tices not related to personal in- tenance practices. jury. DANGER NOTE DANGER indicates a hazardous ○ This note symbol indicates points of situation which, if not avoided, particular interest for more efficient will result in death or serious in-...
FOREWORD Congratulations on your purchase of a new Kawasaki motorcycle. Your new mo- torcycle is the product of Kawasaki’s advanced engineering, exhaustive testing, and continuous striving for superior reliability, safety and performance. Please read this Owner’s Manual carefully before riding so that you will be thoroughly familiar with the proper operation of your motorcycle’s controls, its fea-...
TABLE OF CONTENTS SPECIFICATIONS....... Passing Button: ......47 LOCATION OF PARTS ....... 13 LAP Button: ........47 LOADING AND ACCESSORIES Brake Lever Adjuster......47 INFORMATION ........ 16 Fuel ..........48 GENERAL INFORMATION....19 Fuel Requirements: ...... 48 Meter Instruments ......19 Filling the Tank:......
Fuses ..........160 Spark Plugs........106 General Lubrication......161 Valve Clearance ....... 107 Cleaning Your Motorcycle ....163 Kawasaki Clean Air System ..... 107 STORAGE........... 170 Exhaust Device ........ 108 ENVIRONMENTAL PROTECTION..173 Air Cleaner ........109 LOCATION OF LABELS..... 174...
SPECIFICATIONS ENGINE Type DOHC, 4-cylinder, 4-stroke, liquid-cooled Displacement 599 cm³ (36.6 cu in.) Bore × Stroke 67.0 × 42.5 mm (2.64 × 1.67 in.) Compression Ratio 13.3 : 1 Starting System Electric starter Cylinder Numbering Method Left to right, 1-2-3-4 Firing Order 1-2-4-3 Fuel System...
SPECIFICATIONS Coolant Capacity 2.5 L (2.6 US qt) TRANSMISSION Transmission Type 6-speed, return shift Clutch Type Wet, multi disc Driving System Chain drive Primary Reduction Ratio 1.900 (76/40) Final Reduction Ratio 2.688 (43/16) Overall Drive Ratio 6.638 (Top gear) Gear Ratio 2.714 (38/14) 2.200 (33/15) 1.850 (37/20)
SPECIFICATIONS FRAME Castor 24° Trail 103 mm (4.1 in.) Tire Size: Front 120/70ZR17 M/C (58 W) Rear 180/55ZR17 M/C (73 W) Rim Size: Front J17M/C × MT3.50 Rear J17M/C × MT5.50 Fuel Tank Capacity 17 L (4.5 US gal) ELECTRICAL EQUIPMENT Battery 12 V 8 Ah Headlight...
SPECIFICATIONS Even if one of LED (Light Emitting Diode) tail/brake lights does not go on, consult with an authorized Kawasaki dealer. Specifications are subject to change without notice, and may not apply to every country.
LOCATION OF PARTS LOCATION OF PARTS 1. Clutch Lever 6. Brake Fluid Reservoir (Front) 2. Left Handlebar Switches 7. Right Handlebar Switches 3. Compression Damping Force 8. Front Brake Lever Adjuster (Front Fork) 9. Throttle Grip 4. Rebound Damping Force Adjuster 10.
LOCATION OF PARTS 12. Headlight 21. Tail/Brake Light 29. Rebound Damping 13. Air Cleaner Intake 22. License Plate Light Force Adjuster 14. Turn Signal Light 23. Brake Disc 30. Shift Pedal 15. Spark Plugs 24. Spring Preload 31. Compression 16. Fuel Tank Adjuster Damping Force 17.
LOCATION OF PARTS 34. Fuse Box 40. Rear Brake Pedal 35. Battery 41. Rear Brake Light Switch 36. Fuel Tank Cap 42. Oil Level Inspection Window 37. Muffler 43. Brake Fluid Reservoir (Rear) 38. Swingarm 44. Coolant Reserve Tank 39. Rear Shock Absorber...
Kawasaki Parts Accessories, motorcycle be genuine Kawasaki Kawasaki has no control over the components. design or application of accessories. In some cases, improper installation Because a motorcycle is sensitive to or use of accessories, or motorcycle...
LOADING AND ACCESSORIES INFORMATION following general guidelines have been on the motorcycle center of gravity. prepared to assist you in making your Baggage weight should also be dis- determinations. tributed equally on both sides of the 1. Any passenger should be thor- motorcycle.
LOADING AND ACCESSORIES INFORMATION affected any lighting components, be used to tow any trailers or other road clearance, banking capability vehicles. Kawasaki does not man- (i.e., lean angle), control operation, ufacture sidecars or trailers for mo- wheel travel, front fork movement,...
GENERAL INFORMATION GENERAL INFORMATION Meter Instruments A. MODE Button B. RESET Button C. Shift-Up Indicator Light D. Tachometer E. Red Zone F. Fuel Level Warning Indicator Light G. High Beam Indicator Light H. Neutral Indicator Light I. Turn Signal Indicator Light J.
“ON”, the tachometer needle momen- tarily goes from the minimum to the maximum, then goes back from the maximum to the minimum reading to check its operation. If the tachome- ter does not operate correctly, have it checked by an authorized Kawasaki dealer.
GENERAL INFORMATION Digital Meter: The digital meter displays the fol- lowing functions: the speedometer, clock, trip meter, odometer, coolant temperature meter, stop watch, gear position, oil pressure warning symbol, A. Odometer immobilizer warning symbol, and fuel B. Trip meter C. Stop Watch injection warning symbol.
GENERAL INFORMATION Digital Meter mph·km/h Display - mph·km/h Display can alternate be- tween English and metric modes (mph and km/h) in the digital meter. Make sure that km/h or mph is correctly dis- played according to local regulations before riding. NOTE ○...
GENERAL INFORMATION • • Display the odometer in the digital The mph·km/h (and °C/°F tempera- meter. ture) display shifts as follows. • The mph·km/h (or °C/°F tempera- ture) display shifts by pushing the RESET button while the MODE but- ton pushed in. A.
GENERAL INFORMATION Gear Position - Clock - This display shows the correspond- To adjust hours and minutes: • ing gear position when the transmis- Turn the ignition key to “ON”. • sion is shifted. As the transmission Push the MODE button to display the is shifted, the corresponding gear po- odometer.
GENERAL INFORMATION • NOTE Push the RESET button. The hour ○ display stops flashing and the minute Pushing the MODE button momen- display starts flashing. Push the tarily advances the hour or minute MODE button to advance the min- step by step. Pushing and hold- utes.
GENERAL INFORMATION Odometer - To reset the trip meter: • The odometer shows the total dis- Push the MODE button to display the tance in kilometers or miles that the ve- trip meter. • hicle has been ridden. This meter can- Push the RESET button and hold it not be reset.
GENERAL INFORMATION NOTE Lap Counter/Coolant Temperature ○ Meter - The data is maintained by the back The Lap counter/coolant temperature -up power if the ignition key is turned meter shows either the lap number or off. ○ the coolant temperature. The lap num- When the trip meter reaches 999.9 ber is displayed when in the stop watch while riding, the meter is reset to 0.0...
GENERAL INFORMATION • • When the coolant temperature rises If the coolant temperature rises to to above 40 °C (104 °F), the numer- above 115 °C (239 °F) and below ical value of the coolant temperature 120 °C (248 °F), the numerical value at the present state is displayed.
GENERAL INFORMATION • If the coolant temperature rises to Stop Watch - above 120 °C (248 °F), “HI” is dis- The stop watch can be used in closed played and starts flashing. This course competition. warns the operator that the coolant The stop watch is operated as fol- temperature is too high.
GENERAL INFORMATION • • The stop watch starts timing laps. After each lap, push the LAP button on the left handlebar switch. A. Lap Time A. Lap Button...
GENERAL INFORMATION • • The stop watch starts timing the next To stop the stop watch, push the lap and the previous lap time is dis- START/STOP switch on the right played for ten seconds. handlebar switch to the left. •...
GENERAL INFORMATION • To reset the stop watch and erase all Warning/Indicator Lights: lap numbers and times, push the RE- N : When the transmission is in neutral, SET button for more than two sec- the neutral indicator light goes on. onds.
(FI) in the digital me- gine running, have its cause checked ter flash on whenever the ignition key by an authorized Kawasaki dealer. is turned to “ON” or trouble occurs in Refer to the following each symbol the fuel injection system. After turning...
When the key is turned to “OFF”, have the immobilizer system checked the warning indicator light will start by an authorized Kawasaki dealer. flashing, which indicates that the im- mobilizer system is enabled. After 24 hours have passed, the warning indi- cator light will stop flashing, however the immobilizer system is still enabled.
GENERAL INFORMATION NOTE fuel level warning indicator light goes ○ on and “FUEL” flash. Warning indicator light flashing mode When vehicle stands with Side can be set to either on or off. Push Stand, Fuel Level Warning Indicator and hold the MODE and RESET but- Light cannot show the amount of fuel tons simultaneously for more than in the fuel tank exactly.
GENERAL INFORMATION NOTE Shift Up Indicator Light - ○ The Shift-up indicator light can be When pushing the MODE button used in closed course competition. Do while “FUEL” is displayed, the dis- not use the shift-up indicator during ev- play can be shifted to odometer, trip eryday riding.
GENERAL INFORMATION • • Push the MODE and RESET button To adjust the shift-up engine speed, simultaneously for more than 2 sec- press the RESET button and the shift onds. The previous shift-up engine -up engine speed timing advances in speed setting will be displayed in the 50 r/min (rpm) increments up to 16 tachometer gauge.
GENERAL INFORMATION • WARNING To complete the adjustment, push the MODE button and RESET but- Failing to properly observe the ton simultaneously for more than two road ahead increases the chance seconds. The tachometer now oper- of an accident. Do not concen- ates normally.
Registering additional ig- nition key should be done by an au- thorized Kawasaki dealer. Blank keys are available at your Kawasaki dealers. Ask your dealer to make any additional spare keys you may need, using your original key as a master. To make ad-...
GENERAL INFORMATION NOTICE along with all ignition keys to an au- thorized Kawasaki dealer to have them Do not put two keys of any immo- re-registered. Up to five ignition keys bilizer system on the same key can be registered with the immobilizer ring.
If an improperly coded key is used or any incorrect communication between If all ignition keys are lost, an ECU and key is occurred, the engine authorized Kawasaki dealer will does not start and warning indicator have to replace the ECU and or- light flashes.
GENERAL INFORMATION hold the MODE and RESET buttons EC Directive Compliance simultaneously for more than two This immobilizer system complies seconds, within twenty seconds after with the R & TTE (Radio equipment and turning the ignition key to the “OFF” telecommunications terminal equip- position, then the warning indicator ment and the mutual recognition of...
GENERAL INFORMATION Ignition Switch/Steering Lock Engine off. All electrical This is a four-position, key-operated circuits off. switch. The key can be removed from Engine on. All electrical the switch when it is in the OFF, LOCK, equipment can be used. or P (Park) position.
GENERAL INFORMATION Right Handlebar Switches the engine immediately after turning the ignition key to “ON”. Engine Stop Switch: ○ If you leave the P (Park) position on In addition to the ignition switch, for a long time (one hour), the battery the engine stop switch must be in may become totally discharged.
GENERAL INFORMATION Starter Button: The starter button operates the elec- tric starter when the transmission is in neutral. Refer to the Starting the Engine sec- tion of the “How to Ride the Motorcycle” chapter for starting instructions. START/STOP Switch (Stop Watch): Refer to the Digital Meter section of this chapter for stop watch instructions.
GENERAL INFORMATION Left Handlebar Switches Dimmer Switch: High or low beam can be selected with the dimmer switch. When the headlight is on high beam ( ), the high beam indicator light goes on. High beam..( Low beam..( NOTE ○ A.
GENERAL INFORMATION Brake Lever Adjuster Turn Signal Switch: When the turn signal switch is turned There is an adjuster on the brake lever. The adjuster has 6 positions so to the left ( ) or right ( ), the that the released lever position can be corresponding turn signals flash on and adjusted to suit the operator’s hands.
Never use gasoline with an octane rat- ing lower than the minimum specified by Kawasaki to prevent severe engine damage. The octane rating of a gasoline is a measure of its resistance to detona- A.
GENERAL INFORMATION NOTICE NOTICE Do not use leaded gasoline, as If engine “knocking" or “ping- this will destroy the catalytic ing" occurs, use a different converter. (For further infor- brand of gasoline of a higher mation, refer to the “Catalytic octane rating.
GENERAL INFORMATION *E10 means fuel containing up to Fuel Type Unleaded Gasoline 10% ethanol as specified by European Ethanol E10 or less directive. Content Filling the Tank: Minimum Research Octane Number Avoid filling the tank in the rain or Octane (RON) where heavy dust is blowing so that the Rating...
GENERAL INFORMATION ○ Do not push on the key to close the cap, or the cap cannot be locked. A. Key Hole Cover B. Ignition Key C. Fuel Tank Cap A. Tank Cap NOTE B. Fuel Tank ○ C. Top Level The fuel tank cap cannot be closed D.
GENERAL INFORMATION NOTICE WARNING Gasoline is extremely flammable Certain ingredients in gasoline and can be explosive under cer- may cause paint fading or dam- tain conditions, creating the po- age. Be extra careful not to spill tential for serious burns. Turn fuel during refueling.
GENERAL INFORMATION Side Stand Do not sit on the motorcycle while it is The motorcycle is equipped with a on its side stand. Always kick the stand side stand. fully up before sitting on the motorcycle. NOTE ○ The motorcycle is equipped with a side stand switch.
GENERAL INFORMATION • Seats Remove the bolts and pull off the seat to the up and front. Rider’s Seat Removal • Remove the screw. • Remove the side cover by pulling out it to detach the hook and projection, and hook-and-loop fastener. A.
GENERAL INFORMATION • Rider’s Seat Installation When installing the side cover, insert • Place the tab on the rear of the rider’s the lower side of the cover into the seat into the slot in the frame and frame first, and then insert the upper tighten the bolt.
GENERAL INFORMATION NOTE Passenger’s Seat Removal ○ Remove the passenger’s seat by in- When removing the passenger’s serting the ignition key into the seat seat, pull it up while turning the key. lock, and turning it clockwise. A. Passenger’s Seat A.
GENERAL INFORMATION Passenger’s Seat Installation • Insert the tab on the rear of the pas- senger’s seat into the slot in the frame. • Insert the left and right projections at the front of the passenger’s seat into the left and right holes on the frame. •...
GENERAL INFORMATION WARNING Helmet Hooks Helmets can be secured to the motor- Riding with helmets attached to cycle by the helmet hooks located un- the hooks could cause an ac- der the passenger’s seat. cident by distracting the oper- ator or interfering with normal vehicle operation.
GENERAL INFORMATION Tool Kit Air Cleaner Intake The tool kit is located under the pas- The air cleaner intake allows air to senger’s seat. enter the fuel system. Never allow any- The kit contains tools that are help- thing to restrict the flow of air into the ful in making roadside repairs, adjust- air cleaner.
BREAK-IN BREAK-IN The first 1 600 km (1 000 mi) that the motorcycle is ridden is designated as the break-in period. If the motorcycle is not used carefully during this period, you may very well end up with a “broken down” instead of a “broken in” motorcycle after a few thousand kilometers.
During break-in, avoid sudden and maximum braking and acceleration, and hard cornering. In addition to the above, at 1 000 km (600 mi) it is extremely important that the owner have the initial maintenance service performed by an authorized Kawasaki dealer.
HOW TO RIDE THE MOTORCYCLE HOW TO RIDE THE MOTORCYCLE • Starting the Engine Turn the ignition key to “ON”. • Check that the engine stop switch is NOTE in the position. ○ If the ignition key is turned to “OFF” position, wait a short while (approx.
HOW TO RIDE THE MOTORCYCLE and the starter button pushed in. Af- ter righting the motorcycle, first turn the ignition key to “OFF” and then back to “ON” for a few seconds be- fore starting the engine. • Without holding the throttle grip, push the starter button to start the engine.
HOW TO RIDE THE MOTORCYCLE NOTICE NOTE ○ The motorcycle is equipped with a Do not let the engine idle longer starter lockout switch. This switch is than five minutes, or engine designed so that the engine does not overheating and damage may start if the transmission is in gear and occur.
HOW TO RIDE THE MOTORCYCLE DANGER Jump Starting If your motorcycle battery is “run Battery acid generates hydro- down”, it should be removed and gen gas which is flammable and charged. If this is not practical, a 12 explosive under certain con- volt booster battery and jumper cables ditions.
HOW TO RIDE THE MOTORCYCLE • • Connect a jumper cable from the Connect another jumper cable from positive (+) terminal of the booster the negative (–) terminal of the battery to the positive (+) terminal of booster battery to your motorcy- the motorcycle battery.
HOW TO RIDE THE MOTORCYCLE • DANGER Follow the standard engine starting procedure. Batteries contain sulfuric acid that can cause burns and pro- NOTICE duce hydrogen gas which is highly explosive. Do not make Do not operate the starter con- this last connection at the fuel tinuously for more than 5 sec- system or battery.
HOW TO RIDE THE MOTORCYCLE Moving Off NOTE • ○ Check that the side stand is up. The motorcycle is equipped with a • Pull in the clutch lever. side stand switch. This switch is de- • Shift into 1st gear. signed so that the engine does not •...
HOW TO RIDE THE MOTORCYCLE Shifting Gears NOTE • ○ Close the throttle while pulling in the The transmission is equipped with a clutch lever. positive neutral finder. When the mo- • Shift into the next higher or lower torcycle is standing still, the transmis- gear.
HOW TO RIDE THE MOTORCYCLE • Braking For emergency braking, disregard • downshifting, and concentrate on Close the throttle completely, leav- applying the brakes as hard as pos- ing the clutch engaged (except when sible without skidding. shifting gears) so that the engine will help slow down the motorcycle.
HOW TO RIDE THE MOTORCYCLE Stopping the Engine • Close the throttle completely. • Shift the transmission into neutral. • Turn the ignition key to “OFF”. • Support the motorcycle on a firm, level surface with the side stand. • Lock the steering.
Stopping the Motorcycle in an 2. During removal of the air cleaner, Emergency dirt is allowed to enter and jam the Your Kawasaki Motorcycle has been fuel injection system. designed and manufactured to pro- In an emergency situation such as...
HOW TO RIDE THE MOTORCYCLE WARNING Parking The engine and exhaust system WARNING get extremely hot during normal Operating or parking the vehi- operation and can cause serious cle near flammable materials can burns. cause a fire, and can result in Never touch a hot engine, ex- property damage or severe per- haust pipe, or muffler during op-...
HOW TO RIDE THE MOTORCYCLE NOTE and the motorcycle is not close to ○ any source of flame or sparks; this When stopping near traffic at night, includes any appliance with a pilot you can leave the taillight on for light.
HOW TO RIDE THE MOTORCYCLE WARNING Catalytic Converter This motorcycle is equipped with a Operating or parking the vehi- catalytic converter in the exhaust sys- cle near flammable materials can tem. The converter reacts with car- cause a fire, and can result in bon monoxide, hydrocarbons and nitro- property damage or severe per- gen oxides to convert them into carbon...
HOW TO RIDE THE MOTORCYCLE • Use only unleaded gasoline. Never use leaded gasoline. Leaded gaso- line significantly reduces the capabil- ity of the catalytic converter. • Do not coast the vehicle with the igni- tion switch and/or engine stop switch off.
SAFE OPERATION SAFE OPERATION Safe Riding Technique The points given below are applicable for everyday motorcycle use and should be carefully observed for safe and effective vehicle operation. For safety, eye protection and a When riding always keep both helmet are strongly recommended. hands on the handlebars and both You should be aware of and verify feet on the footpegs.
SAFE OPERATION In general your actions should In wet conditions, rely more on the be smooth as sudden acceleration, throttle to control vehicle speed and braking or turning may cause loss less on the front and rear brakes. of control, especially when riding in The throttle should also be used ju- wet conditions or on loose roadway diciously to avoid skidding the rear...
SAFE OPERATION Do not downshift at too high an Avoiding unnecessary weaving is r/min (rpm) to avoid damage from important to the safety of both the overrevving to the engine. rider and other motorists.
SAFE OPERATION Daily Safety Checks Check the following items each day before you ride. The time required is minimal, and habitual performance of these checks will help ensure you a safe, reliable ride. If any irregularities are found during these checks, refer to the Maintenance and Adjustment chapter or see your dealer for the action required to return the motor- cycle to a safe operating condition.
SAFE OPERATION Tires ......Air pressure (when cold): Front 250 kPa (2.50 kgf/cm², 36 psi) Rear 290 kPa (2.90 kgf/cm², 42 psi) Install the air valve cap. Drive chain ....Slack 30 ∼ 40 mm (1.2 ∼ 1.6 in.). Lubricate when chain is dry. Nuts, bolts, fasteners ..
SAFE OPERATION Side stand ....Return to its fully up position by spring tension. Return spring not weak or not damaged. Refer to the “Daily Safety Checks” caution label attached to the back of left side cover.
SAFE OPERATION Additional Considerations for High Speed Operation Brakes: The importance of the brakes, especially during high speed operation, cannot be overemphasized. Check to see that they are correctly adjusted and func- tioning properly. Steering: Looseness in the steering can cause loss of control. Check to see that the handlebar turns freely but has no play.
SAFE OPERATION WARNING Handling characteristics of a motorcycle at high speeds may vary from those you are familiar with at legal highway speeds. Do not attempt high speed operation unless you have received sufficient training and have the required skills.
MAINTENANCE AND ADJUSTMENT Periodic Maintenance Chart 1. Periodic Inspection (Engine Related Items) Frequency Whichever comes *Odometer Reading first km × 1 000 (mile × 1 000) Page Operation (Engine Every Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Valve clearance - Every 42 000 km (26 250 mile) inspect Throttle control system...
MAINTENANCE AND ADJUSTMENT Frequency Whichever comes *Odometer Reading first km × 1 000 (mile × 1 000) Page Operation (Engine Every Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Fuel hoses damage - • • • • year – inspect Fuel hoses installation •...
MAINTENANCE AND ADJUSTMENT 2. Periodic Inspection (Chassis Related Items) Frequency Whichever comes *Odometer Reading first km × 1 000 (mile × 1 000) Page Operation (Chassis Every Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Clutch and drive train: Clutch operation (play, engagement, •...
MAINTENANCE AND ADJUSTMENT Frequency Whichever comes *Odometer Reading first km × 1 000 (mile × 1 000) Page Operation (Chassis Every Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Wheels and tires: Tire air pressure - • • • year inspect Wheels/tires damage •...
MAINTENANCE AND ADJUSTMENT Frequency Whichever comes *Odometer Reading first km × 1 000 (mile × 1 000) Page Operation (Chassis Every Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Brake hoses damage • • • • • • • year - inspect Brake pad wear - •...
MAINTENANCE AND ADJUSTMENT Frequency Whichever comes *Odometer Reading first km × 1 000 (mile × 1 000) Page Operation (Chassis Every Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Suspensions: Front forks/rear shock absorber 139/ • • • operation (damping and smooth stroke) - inspect Front forks/rear...
MAINTENANCE AND ADJUSTMENT Frequency Whichever comes *Odometer Reading first km × 1 000 (mile × 1 000) Page Operation (Chassis Every Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Steering system: Steering play - • • • • year – inspect Steering stem •...
MAINTENANCE AND ADJUSTMENT Frequency Whichever comes *Odometer Reading first km × 1 000 (mile × 1 000) Page Operation Every (Chassis Items) (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Electrical system: Lights and switches • • • year – operation - inspect Headlight aiming - •...
MAINTENANCE AND ADJUSTMENT 3. Periodic Replacement Frequency Whichever comes *Odometer Reading first km × 1 000 (mile × 1 000) Page Change/Replace- Every ment Items (0.6) (7.5) (15) (22.5) (30) Air cleaner element # every 18 000 km (11 250 mile) - replace •...
• K Spark plug - replace K : Should be serviced by an authorized Kawasaki dealer. * : For higher odometer readings, repeat at the frequency interval established here. # : Service more frequently when operating in severe conditions: dusty, wet, muddy,...
MAINTENANCE AND ADJUSTMENT Engine Oil Oil Level Inspection • In order for the engine, transmission, If the oil has just been changed, start and clutch to function properly, main- the engine and run it for several min- tain the engine oil at the proper level, utes at idle speed.
MAINTENANCE AND ADJUSTMENT • • Check the engine oil level through If the oil level is too high, remove the the oil level inspection window. With excess oil through the oil filler open- the motorcycle held level, the oil level ing using a syringe or some other should come up between the upper suitable device.
The oil change and oil filter replacement should be done by an authorized Kawasaki dealer. A. Oil Pressure Warning Symbol B. Warning Indicator Light A. Engine Oil Drain Plug...
MAINTENANCE AND ADJUSTMENT Tightening Torque Engine Oil Drain Plug: 29 N·m (3.0 kgf·m, 21 ft·lb) Cartridge: 17 N·m (1.7 kgf·m, 13 ft·lb) Recommended Engine Oil Type: API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 Viscosity: A.
MAINTENANCE AND ADJUSTMENT Engine Oil Capacity Capacity: 2.8 L (3.0 US qt) [when filter is not removed] 3.1 L (3.3 US qt) [when filter is removed] 3.6 L (3.8 US qt) [when engine is completely dry] Although 10W-40 engine oil is the recommended oil for most condi- tions, the oil viscosity may need to be changed to accommodate atmo-...
MAINTENANCE AND ADJUSTMENT NOTICE Cooling System Radiator and Cooling Fan - Using high-pressure water, as Check the radiator fins for obstruc- from a car wash facility, could tion by insects or mud. Clean off damage the radiator fins and im- any obstructions with a stream of pair the radiator’s effectiveness.
MAINTENANCE AND ADJUSTMENT Coolant - a period of time, the cooling system Coolant absorbs excessive heat from accumulates rust and scale in the wa- the engine and transfers it to the air ter jacket and radiator. This will clog at the radiator. If the coolant level be- up the coolant passages, and con- comes low, the engine overheats and siderably reduce the efficiency of the...
MAINTENANCE AND ADJUSTMENT NOTICE NOTICE If hard water is used in the sys- Permanent types of antifreeze on tem, it causes scale accumula- the market have anti-corrosion tion in the water passages, and and anti-rust properties. When it considerably reduces the effi- is diluted excessively, it loses its ciency of the cooling system.
MAINTENANCE AND ADJUSTMENT • NOTE Check the coolant level through the ○ coolant level gauge on the reserve Check the level when the engine is tank located to the right of the engine. cold (room or atmospheric tempera- The coolant level should be between ture).
Have the cooling system inspected by your authorized Kawasaki A. Reserve Tank Cap dealer. Coolant Change Have the coolant changed by an au-...
The standard spark plug is shown in the table. The spark plugs should be replaced in accordance with the Peri- odic Maintenance Chart. Spark plug removal should be done by an authorized Kawasaki dealer. Spark Plug Standard NGK CR9E Plug: A.
Valve clearance for each valve monoxide into carbon dioxide. should be checked and adjusted in accordance with the Periodic Mainte- nance Chart. Inspection and adjustment should be done by an authorized Kawasaki dealer.
ECU, in accordance with the Periodic Main- and adjustment or maintenance should tenance Chart. Also, inspect the air be done by an authorized Kawasaki suction valves whenever stable idling dealer. cannot be obtained, engine power is greatly reduced, or there are abnormal engine noises.
MAINTENANCE AND ADJUSTMENT NOTICE Air Cleaner A clogged air cleaner restricts the en- Do not adjust the exhaust device gine’s air intake, increasing fuel con- system by yourself. The mal- sumption, reducing engine power, and adjustment will cause the poor causing spark plug fouling.
• NOTICE Remove the Rider’s seat (refer to Rider’s Seat Removal in General In- Use only the recommended air formation chapter). cleaner element (Kawasaki part • Remove the bracket bolt. number 11013-0036). Using other air cleaner elements will wear the engine prematurely or lower the engine performance.
MAINTENANCE AND ADJUSTMENT • • Raise the front of the fuel tank. Pull up the air cleaner element. • Remove the air cleaner housing cover screws and cover. A. Element B. Pull Up A. Screws B. Air Cleaner Housing Cover...
MAINTENANCE AND ADJUSTMENT • • Put a clean, lint-free towel over the Element and fuel tank installation is air cleaner element duct to keep dirt performed in the reverse order of re- or other foreign material from enter- moval. • ing.
MAINTENANCE AND ADJUSTMENT • WARNING Run the throttle cables and clutch ca- ble as shown in the figure. Do not pinch the cables between the bracket and the frame. Op- eration with incorrectly routed or damaged cables could result in an unsafe riding condition.
MAINTENANCE AND ADJUSTMENT • Oil Draining If there is any oil in the reservoir, re- • Inspect the transparent reservoir lo- move the reservoir and drain the oil. cated on the left side of the engine to WARNING see if any oil or water has run down from the air cleaner housing.
MAINTENANCE AND ADJUSTMENT Throttle Control System Inspection • Check the throttle grip play each day Check that the throttle grip play is before riding the motorcycle, and carry correct by lightly turning the throttle out the maintenance and adjustments grip back and forth. in accordance with the Periodic Main- tenance Chart.
MAINTENANCE AND ADJUSTMENT Throttle Grip Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) • If there is improper play, adjust it. Adjustment • Loosen the locknuts at the upper of the throttle cables, and turn both throttle cable adjusters completely so as to give the throttle grip plenty of play.
MAINTENANCE AND ADJUSTMENT Idle Speed Idle Speed The idle speed adjustment should be 1 250 ∼ 1 350 r/min (rpm) performed in accordance with the Pe- riodic Maintenance Chart or whenever the idle speed is disturbed. Adjustment • Start the engine, and warm it up thor- oughly.
Replace damaged Inspection control cables before operation. • Check that the clutch lever operates properly and that the inner cable slides smoothly. If there is any irreg- ularity, have the clutch cable checked by an authorized Kawasaki dealer.
MAINTENANCE AND ADJUSTMENT • Check the clutch lever play as shown Adjustment • in the figure. Turn the adjuster so that the clutch lever will have the proper play. Clutch Lever Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) WARNING Too much cable play can pre- vent clutch disengagement and...
MAINTENANCE AND ADJUSTMENT • Drive Chain If it cannot be done, use the nuts at the lower end of the clutch cable. The drive chain slack and lubrication must be checked each day before rid- ing the motorcycle and must be main tained in accordance with the Periodic Maintenance Chart for safety and to prevent excessive wear.
MAINTENANCE AND ADJUSTMENT • Chain Slack Inspection If the drive chain is too tight or too • Set the motorcycle up on its side loose, adjust it so that the chain slack stand. will be within the standard value. • Rotate the rear wheel to find the po- Drive Chain Slack sition where the chain is tightest, and...
MAINTENANCE AND ADJUSTMENT • Chain Slack Adjustment If the chain is too loose, turn out the • Loosen the left and right chain ad- left and right chain adjusters evenly. • juster locknuts. If the chain is too tight, turn in the left •...
MAINTENANCE AND ADJUSTMENT NOTE ○ Wheel alignment also checked using the straightedge or string method. WARNING Misalignment of the wheel will result in abnormal wear, and may result in an unsafe riding con- dition. Align the rear wheel us- A. Marks ing the marks on the swingarm B.
When inserting the cotter pin, if the this item should be serviced by an slots in the nut do not align with authorized Kawasaki dealer. the cotter pin hole in the axle shaft, tighten the nut clockwise up to the •...
MAINTENANCE AND ADJUSTMENT WARNING Wear Inspection • Remove the front footpeg bracket A loose axle nut can lead to an bolts. accident resulting in serious in- jury or death. Tighten the axle nut to the proper torque and in- stall a new cotter pin. •...
MAINTENANCE AND ADJUSTMENT • NOTE Remove the bolts and quick rivet. • ○ Remove the chain cover. The chain cover uses the quick rivet. The quick rivet can be removed by pushing the center pin into the quick rivets, and when installing it, pull the center pin fully up first, and then push into the center pin after inserting it.
MAINTENANCE AND ADJUSTMENT • Quick Rivet Installation Stretch the chain taut either by using the chain adjusters, or by hanging a 10 kg (22 lb) weight on the chain. • Measure the length of 20 links on the straight part of the chain from pin center of the 1st pin to pin center of the 21st pin.
Front Footpeg Bracket Bolt: 25 N·m (2.5 B. Weight kgf·m, 18 ft·lb) WARNING For safety, use only the standard chain. It is an endless type and should not be cut for installa- tion; have it installed by an au- thorized Kawasaki dealer.
Also inspect the sprockets for un- wear limits. evenly or excessively worn teeth, and damaged teeth. A. Good Teeth B. Worn Teeth C. Damaged Teeth • If there is any irregularity, have the drive chain and/or the sprockets re- placed by an authorized Kawasaki dealer.
MAINTENANCE AND ADJUSTMENT • Lubrication Apply oil to the sides of the rollers so Lubrication is also necessary after that it will penetrate to the rollers and riding through rain or on wet roads, or bushings. Apply oil to the O-rings so any time that the chain appears dry.
1 mm (0.04 in.), replace both pads changed if it becomes contaminated in the caliper as a set. Pad replace- with dirt or water. ment should be done by an authorized Kawasaki dealer. Fluid Requirement Use heavy-duty brake fluid only from a container marked DOT4. NOTICE Do not spill brake fluid onto any painted surface.
MAINTENANCE AND ADJUSTMENT Fluid Level Inspection • With the brake fluid reservoirs held horizontal, the brake fluid level must be kept between the upper and lower level lines. A. Rear Brake Fluid Reservoir B. Upper Level Line C. Lower Level Line D.
MAINTENANCE AND ADJUSTMENT • NOTE If the fluid level in either reservoir is ○ lower than the lower level line, check First, tighten until slight resistance is for fluid leaks in the brake lines, and felt, which indicates indicating that fill the reservoir to the upper level the cap is seated on the reservoir line.
• If it does not, ask an authorized Air in the brake lines diminish Kawasaki dealer to inspect the front braking performance and can brake light switch. cause an accident resulting in injury or death. If the brake lever...
MAINTENANCE AND ADJUSTMENT • Check the operation of the rear brake Adjustment • light switch by depressing the brake To adjust the rear brake light switch, pedal. The brake light should go on move the switch up or down by turn- after the proper pedal travel.
When adjust- ing the damping adjuster for use in a closed course, adjustment should be done by an authorized Kawasaki dealer. The steering operation should be checked and the steering damper unit...
MAINTENANCE AND ADJUSTMENT Damping Force Adjustment Steering Damping Adjuster Standard Setting When adjusting the damping force of the steering damper, turn the damp- 18 clicks* ing force adjuster clockwise or counter- clockwise as the following figure. : Fully turned to the softer direction A.
If any doubt about the front fork, it The front fork operation and oil leak- should be done by an authorized age should be checked in accordance Kawasaki dealer. with the Periodic Maintenance Chart. Front Fork Inspection • Holding the brake lever, pump the front fork up and down several times to inspect smooth stroke.
MAINTENANCE AND ADJUSTMENT NOTICE force can be adjusted for different rid- ing and loading conditions. Weaker Do not force to turn the rebound spring force and damping force are and compression damping force for comfortable riding, but they should adjuster from the fully seated po- be increased for high speed riding or sition, or the adjusting mecha- riding on rough roads.
MAINTENANCE AND ADJUSTMENT Spring Preload Adjustment Compression Damping Force Adjuster • Turn the spring preload adjuster all Rebound Damping Force the way counterclockwise with the Adjuster Adjustment • hexagon wrench to make the spring Turn the adjuster all the way clock- force weakest.
MAINTENANCE AND ADJUSTMENT WARNING If both spring preload adjusters and both rebound and compres- sion damping force adjusters are not adjusted equally, han- dling may be impaired and haz- ardous condition may result. Always adjust the suspension components equally. A. Compression Damping Force Adjuster B.
MAINTENANCE AND ADJUSTMENT Rear Shock Absorber The standard setting positions of the spring preload adjuster, rebound The rear shock absorber operation damping force adjuster and compres- and oil leakage should be checked in sion damping force adjuster for an accordance with the Periodic Mainte- average-build rider of 68 kg (150 lb) nance Chart.
If there is any doubt about the rear Before making any adjustments, shock absorber, it should be checked however, read the following proce- by an authorized Kawasaki dealer. dures: NOTICE Do not force to turn the rebound and compression damping force...
MAINTENANCE AND ADJUSTMENT Rebound Damping Force Adjustment Compression Damping Force The rebound damping force adjuster Adjustment is located at the lower end of the rear The compression damping force ad- shock absorber. juster is located on the gas reservoir at the upper end of the rear shock ab- sorber.
MAINTENANCE AND ADJUSTMENT NOTE to decrease high speed compression ○ damping. Turning the high speed adjuster has the low speed adjuster turning. Al- though the low speed adjuster turns with the high speed adjuster when turning the high speed adjuster, the low speed adjuster setting position dose not change.
MAINTENANCE AND ADJUSTMENT Wheels Tubeless tires are installed on the wheels of this motorcycle. The indica- tions of TUBELESS on the tire side wall and the rim show that the tire and rim are specially designed for tubeless use. A. TUBELESS Mark A.
MAINTENANCE AND ADJUSTMENT WARNING The tire and rim form a leakproof unit by making airtight contacts at the tire Installing a tube inside a tube- chamfers and the rim flanges instead less-type tire can create exces- of using an inner tube. sive heat build up that can dam- age the tube and cause rapid deflation.
MAINTENANCE AND ADJUSTMENT ○ Tires - Tire pressure is affected by changes in ambient temperature and altitude, Payload and Tire Pressure and so the tire pressure should be Failure to maintain proper inflation checked and adjusted when your rid- pressures or observe payload limits for ing involves wide variations in tem- your tires may adversely affect han- perature or altitude.
MAINTENANCE AND ADJUSTMENT • In accordance with the Periodic Tire Air Pressure (when cold) Maintenance Chart, measure the Front 250 kPa (2.50 kgf/cm², 36 psi) depth of the tread with a depth Rear 290 kPa (2.90 kgf/cm², 42 psi) gauge, and replace any tire that has worn down to the minimum al- Tire Wear, Damage lowable tread depth.
MAINTENANCE AND ADJUSTMENT WARNING Minimum Tread Depth 1 mm Tires that have been punctured Front — (0.04 in.) and repaired do not have the Under 130 km/h 2 mm same capabilities as undam- (0.08 in.) (80 mph) aged tires and can suddenly fail, Rear causing an accident resulting 3 mm...
MAINTENANCE AND ADJUSTMENT ○ WARNING When operating on public roadways, keep maximum speed under traffic New tires are slippery and may law limits. cause loss of control and injury. Standard Tire (Tubeless) A break-in period of 160 km (100 miles) is necessary to estab- Size: 120/70ZR17 M/C (58 W) lish normal tire traction.
MAINTENANCE AND ADJUSTMENT Battery Due to their internal composition, The battery installed in this motorcy- batteries continually self discharge. cle is a sealed type, so it is not nec- The discharge rate depends on the essary to check the battery electrolyte type of battery and ambient temper- level or add distilled water.
MAINTENANCE AND ADJUSTMENT Self-discharge Current Drain Approx. Number of Days Days from Days from From 100% Charged to 100% 100% Discharging 100% discharged charged to charged to Ampere Temperature 100% Lead Lead Discharged Discharged -Antimony -Calcium 7 mA 60 Days 119 Days Battery Battery...
12.8 volts, the battery should be tion is not warrantable. charged using an appropriate charger (check with your Kawasaki dealer). If you will not be using the motorcy- cle for longer than two weeks, the battery should be charged using an appropriate charger.
If the above chargers are not avail- Do not install a conventional able, use equivalent one. battery in this motorcycle, or the For more details, ask your Kawasaki electrical system cannot work dealer. properly. Battery Charging •...
MAINTENANCE AND ADJUSTMENT • Battery Removal Take the battery out of the case. • • Remove the rider’s seat (refer to Clean the battery using a solution of Rider’s Seat Removal in General baking soda and water. Be sure that Information chapter).
MAINTENANCE AND ADJUSTMENT NOTICE Headlight Beam Installing the (–) cable to the (+) Horizontal Adjustment terminal of the battery or the (+) The headlight beam is adjustable cable to the (–) terminal of the horizontally. If not properly adjusted horizontally, the beam will point to one battery can seriously damaged side rather than straight ahead.
MAINTENANCE AND ADJUSTMENT NOTICE Vertical Adjustment The headlight beam is adjustable ver- When handling quartz tically. If adjusted too low, neither low -halogen bulbs, never touch the nor high beam will illuminate the road glass portion with bare hands. far enough ahead. If adjusted too high, Always use a clean cloth.
If a fuse fails during operation, inspect the electrical system to determine the cause, and then replace it with a new fuse of proper amperage. The main fuse removal should be done by an authorized Kawasaki dealer. A. Main Fuse WARNING Substituting fuses can cause wiring to overheat, catch fire and/or fail.
MAINTENANCE AND ADJUSTMENT General Lubrication Lubricate the points shown below, with either motor oil or regular grease, in accordance with the Periodic Main- tenance Chart or whenever the vehicle has been operated under wet or rainy conditions. Before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime.
(K) Clutch Inner Cable Upper End • pressure cable lubber - (K) Throttle Inner Cable Upper Ends • (K) Clutch Inner Cable • (K) Throttle Inner Cables (K): Should be serviced by an authorized Kawasaki dealer. NOTE ○ After connecting the cables, adjust them.
General Precautions Build-up of debris or flammable Frequent and proper care of your material in and around the vehi- Kawasaki motorcycle will enhance cle chassis, engine, and exhaust its appearance, optimize overall per- can cause mechanical problems formance, and extend its useful life.
MAINTENANCE AND ADJUSTMENT • • Be sure the engine and exhaust are Gasoline, brake fluid, and coolant cool before washing. will damage the finish of painted and • Avoid applying degreaser to seals, plastic surfaces: wash them off im- brake pads, and tires. mediately.
MAINTENANCE AND ADJUSTMENT • Washing Your Motorcycle After cleaning your motorcycle, • Rinse your bike with cold water from check the rubber boot covering the a garden hose to remove any loose shift pedal ball joint for correct instal- dirt. lation.
MAINTENANCE AND ADJUSTMENT • • If the boot is damaged, replace it with Start the engine and let it idle for sev- a new one. If the boot is not po- eral minutes. The heat from the en- sitioned in the groove correctly, re- gine will help dry moist areas.
• If any doubt, consult an authorized on all metal and chrome surfaces to Kawasaki dealer. prevent corrosion. ○ Condensation may form on the inside Windshield and Other Plastic Parts of the headlight lens after riding in the...
MAINTENANCE AND ADJUSTMENT NOTICE Chrome and Aluminum Chrome and uncoated aluminum Plastic parts may deteriorate parts can be treated with a chrome/alu- and break if they come in con- minum polish. Coated aluminum tact with chemical substances should be washed with a mild neu- or household cleaning products tral detergent and finished with a spray such as gasoline, brake fluid,...
MAINTENANCE AND ADJUSTMENT WARNING The sidewalls of tires and other rub- ber components should be treated with Rubber protectants can be slip- a rubber protectant to help prolong their pery and, if used on the tread useful life. area, cause loss of traction re- sulting in accident causing in- jury or death.
STORAGE STORAGE Preparation for Storage - • Clean the entire vehicle thoroughly. • Run the engine for about five minutes to warm the oil, shut it off, and drain the engine oil. WARNING Engine oil is a toxic substance. Dispose of used oil properly. Contact your local authorities for approved disposal methods or possible recy- cling.
STORAGE WARNING Gasoline is extremely flammable and can be explosive under certain con- ditions, creating the potential for serious burns. Turn the ignition key to “OFF”. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.
STORAGE • Put a cover over the motorcycle to keep dust and dirt from accumulating on it. Preparation after Storage - • Remove the plastic bags from the mufflers. • Install the battery in the motorcycle and charge the battery if necessary. •...
If any label is missing, damaged, or worn, get a replacement from your Kawasaki dealer and install it in the correct posi- tion. 1. Brake Fluid (Front) NOTE ○...
LOCATION OF LABELS 2. Important Drive Chain Information 3. Tire and Load Data 4. Brake Fluid (Rear) 5. Fuel Notice...
LOCATION OF LABELS 6. Battery Poison/Danger...
LOCATION OF LABELS 1)/4) 1. Read Owner’s Manual 2. Drive chain slack, see page 122...
LOCATION OF LABELS 1. Read Owner’s Manual 2. Tire Pressure, see page 150 3. Front tire size and manufacture, see page 152 4. Rear tire size and manufacture, see page 152 5. Maximum load, see page 149...
LOCATION OF LABELS 1. Read Owner’s Manual 2. Unleaded gasoline, see page 50 3. Octane rating of gasoline, see page...